Miller MG203123V Owner's manual

Category
Welding System
Type
Owner's manual

This manual is also suitable for

OM-257722J 2016−05
Processes
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Wire Feeder
File: MIG (GMAW)
R
SuitCase
X-TREME 12VS
With ArcReach
CE And Non-CE Models
R
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
Thank you and congratulations on choosing Miller. Now you can get
the job done and get it done right. We know you don’t have time to do
it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owners Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
Working as hard as you do
− every power source from
Miller is backed by the most
hassle-free warranty in the
business.
From Miller to You
Mil_Thank 2009−09
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1.................................
1-1. Symbol Usage 1.......................................................................
1-2. Arc Welding Hazards 1.................................................................
1-3. Additional Symbols For Installation, Operation, And Maintenance 3.............................
1-4. California Proposition 65 Warnings 4......................................................
1-5. Principal Safety Standards 4.............................................................
1-6. EMF Information 4.....................................................................
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5...........................
2-1. Symboles utilisés 5.....................................................................
2-2. Dangers relatifs au soudage à l’arc 5......................................................
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7.....
2-4. Proposition californienne 65 Avertissements 8..............................................
2-5. Principales normes de sécurité 8.........................................................
2-6. Informations relatives aux CEM 8.........................................................
SECTION 3 − DEFINITIONS 9..................................................................
3-1. Additional Safety Symbols And Definitions 9................................................
3-2. Miscellaneous Symbols And Definitions 10..................................................
SECTION 4 − SPECIFICATIONS 11..............................................................
4-1. Serial Number And Rating Label Location 11................................................
4-2. Unit Specifications 11....................................................................
4-3. Environmental Specifications 11...........................................................
4-4. Wire Type, Size, and Feed Speed Capability Table 11.........................................
4-5. Gun Recommendation Table 11...........................................................
SECTION 5 − INSTALLATION 12................................................................
5-1. Equipment Connection Diagram 12........................................................
5-2. ArcReach Applications 12................................................................
5-3. Associating Wire Feeder To ArcReach Compatible Power Source Or ArcReach
Control Quick Setup Guide 12.............................................................
5-4. Equipment Setup 13.....................................................................
5-5. Installing Drive Rolls 14..................................................................
5-6. Connecting Welding Gun And Voltage Sensing Clamp 15......................................
5-7. Connecting Shielding Gas 16.............................................................
5-8. Connecting Weld Cable 16...............................................................
5-9. Selecting Cable Sizes* 17................................................................
5-10. Installing And Threading Welding Wire 18...................................................
5-11. Motor Board (PC1) DIP Switch Settings 18..................................................
5-12. Meter Board (PC22) DIP Switch Settings 20.................................................
SECTION 6 − OPERATION 22...................................................................
6-1. Controls 22............................................................................
6-2. Wire Speed Dual Schedule 23............................................................
6-3. Wire Speed Control Settings 24...........................................................
SECTION 7 − MAINTENANCE & TROUBLESHOOTING 25.........................................
7-1. Routine Maintenance 25.................................................................
7-2. Overload Protection And Thermostat Protection 25...........................................
7-3. Cleaning Debris From Shielding Gas Filter Fitting 26..........................................
7-4. Troubleshooting 27......................................................................
7-5. Diagnostics 29.........................................................................
SECTION 8 − ELECTRICAL DIAGRAM 30........................................................
SECTION 9 − PARTS LIST 32...................................................................
WARRANTY
DECLARATION OF CONFORMITY
for European Community (CE marked) products.
MILLER Electric Mfg. Co., 1635 Spencer Street, Appleton, WI 54914 U.S.A. declares that the
product(s) identified in this declaration conform to the essential requirements and provisions of
the stated Council Directive(s) and Standard(s).
Product/Apparatus Identification:
Product
Stock Number
SUITCASE XTREME 12VS, HEAVY DUTY
DRIVE, ARCREACH
301032
Council Directives:
2014/35/EU Low Voltage
2014/30/EU Electromagnetic Compatibility
2011/65/EU Restriction of the use of certain hazardous substances in electrical and electronic equipment
Standards:
IEC 609745:2013 Arc Welding Equipment – Part 5: Wire feeders
IEC 6097410:2007 Arc Welding Equipment – Part 10: Electromagnetic compatibility (EMC) requirements
Signatory:
_____________________________________ ___________________________________________
David A. Werba
Date of Declaration
MANAGER, PRODUCT DESIGN COMPLIANCE
May 9, 2016
276010A
OM-257722 Page 1
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING
som 2015−09
7
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or ex-
plained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym-
bols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-5. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
Touching live electrical parts can cause fatal shock
s
or severe burns. The electrode and work circuit i
s
electrically live whenever the output is on. The inpu
t
power circuit and machine internal circuits are also
live when power is on. In semiautomatic or automati
c
wire welding, the wire, wire reel, drive roll housing
,
and all metal parts touching the welding wire are
electrically live. Incorrectly installed or improperl
y
grounded equipment is a hazard.
D Do not touch live electrical parts.
ELECTRIC SHOCK can kill.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the follow-
ing electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoid-
able or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit volt-
age. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install, ground, and operate this equipment according to
its Owners Manual and national, state, and local codes.
D Always verify the supply ground − check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conduc-
tor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord and ground conductor for
damage or bare wiring – replace immediately if damaged – bare
wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or repaired cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Do not touch electrode holders connected to two welding ma-
chines at the same time since double open-circuit voltage will be
present.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal. Disconnect cable for process not in
use.
D Use GFCI protection when operating auxiliary equipment in damp
or wet locations.
SIGNIFICANT DC VOLTAGE exists in inverter weld-
ing power sources AFTER removal of input power.
D Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section
before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on
equipment.
D To handle hot parts, use proper tools and/or wear heavy, insu-
lated welding gloves and clothing to prevent burns.
OM-257722 Page 2
Welding produces fumes and gases. Breathing
these fumes and gases can be hazardous to your
health.
FUMES AND GASES can be hazardous.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases. The recommended way
to determine adequate ventilation is to sample for the composition
and quantity of fumes and gases to which personnel are exposed.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturers instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watch-
person nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breath-
ing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying op-
erations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
D Wear an approved welding helmet fitted with a proper shade of
filter lenses to protect your face and eyes from arc rays and
sparks when welding or watching (see ANSI Z49.1 and Z87.1
listed in Safety Standards).
D Wear approved safety glasses with side shields under your
helmet.
D Use protective screens or barriers to protect others from flash,
glare and sparks; warn others not to watch the arc.
D Wear body protection made from durable, flame−resistant mate-
rial (leather, heavy cotton, wool). Body protection includes
oil-free clothing such as leather gloves, heavy shirt, cuffless
trousers, high shoes, and a cap.
ARC RAYS can burn eyes and skin.
Welding on closed containers, such as tanks,
drums, or pipes, can cause them to blow up. Sparks
can fly off from the welding arc. The flying sparks, hot
workpiece, and hot equipment can cause fires and
burns. Accidental contact of electrode to metal objects can cause
sparks, explosion, overheating, or fire. Check and be sure the area is
safe before doing any welding.
WELDING can cause fire or explosion.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
D Do not weld on containers that have held combustibles, or on
closed containers such as tanks, drums, or pipes unless they are
properly prepared according to AWS F4.1 and AWS A6.0 (see
Safety Standards).
D Do not weld where the atmosphere can contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire
hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear body protection made from durable, flame−resistant material
(leather, heavy cotton, wool). Body protection includes oil-free
clothing such as leather gloves, heavy shirt, cuffless trousers, high
shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or by-
pass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
D Read and understand the Safety Data Sheets (SDSs) and the
manufacturers instructions for adhesives, coatings, cleaners,
consumables, coolants, degreasers, fluxes, and metals.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side
shields even under your welding helmet.
BUILDUP OF GAS can injure or kill.
D Shut off compressed gas supply when not in use.
D Always ventilate confined spaces or use
approved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EM
F)
can affect Implanted Medical Devices.
D Wearers of Pacemakers and other Implante
d
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their docto
r
and the device manufacturer before going near arc welding, spo
t
welding, gouging, plasma arc cutting, or induction heating
operations.
Noise from some processes or equipment can
damage hearing.
D Wear approved ear protection if noise lev-
el is high.
NOISE can damage hearing.
Compressed gas cylinders contain gas under high
pressure. If damaged, a cylinder can explode. Since
gas cylinders are normally part of the welding
process, be sure to treat them carefully.
CYLINDERS can explode if damaged.
D Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
D Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
D Keep cylinders away from any welding or other electrical circuits.
D Never drape a welding torch over a gas cylinder.
D Never allow a welding electrode to touch any cylinder.
D Never weld on a pressurized cylinder − explosion will result.
D Use only correct compressed gas cylinders, regulators, hoses,
and fittings designed for the specific application; maintain them
and associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve. Do
not stand in front of or behind the regulator when opening the valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient num-
ber of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
OM-257722 Page 3
1-3. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manu-
ally lifting heavy parts or equipment.
OVERUSE can cause OVERHEATING
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
WELDING WIRE can injure.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
BATTERY EXPLOSION can injure.
D Do not use welder to charge batteries or jum
p
start vehicles unless it has a battery chargin
g
feature designed for this purpose.
MOVING PARTS can injure.
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when maintenance is
finished and before reconnecting input power.
READ INSTRUCTIONS.
D Read and follow all labels and the Owners
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
D The user is responsible for having a qualified electrician prompt-
ly correct any interference problem resulting from the installa-
tion.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
ARC WELDING can cause interference.
D Electromagnetic energy can interfere with
sensitive electronic equipment such as
computers and computer-driven equipment
such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
D To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
D Locate welding operation 100 meters from any sensitive elec-
tronic equipment.
D Be sure this welding machine is installed and grounded
according to this manual.
D If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
OM-257722 Page 4
1-4. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
1-5. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-
net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-6. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). The current from arc welding (and allied pro-
cesses including spot welding, gouging, plasma arc cutting, and
induction heating operations) creates an EMF field around the welding
circuit. EMF fields can interfere with some medical implants, e.g. pace-
makers. Protective measures for persons wearing medical implants
have to be taken. For example, restrict access for passers−by or con-
duct individual risk assessment for welders. All welders should use the
following procedures in order to minimize exposure to EMF fields from
the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recom-
mended.
OM-257722 Page 8
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
LE RAYONNEMENT HAUTE
FRÉQUENCE (H.F.) risque de
provoquer des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équi-
pements de radio−navigation et de communication, les services
de sécurité et les ordinateurs.
D Demander seulement à des personnes qualifiées familiarisées avec
des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distan-
ce correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
D L’énergie électromagnétique risque de
provoquer des interférences pour l’équipement
électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
D Veiller à ce que tout l’équipement de la zone de soudage soit com-
patible électromagnétiquement.
D Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser aussi
bas que possible (ex. par terre).
D Veiller à souder à une distance de 100 mètres de tout équipement
électronique sensible.
D Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
D En cas d’interférences après avoir pris les mesures précédentes,
il incombe à l’utilisateur de prendre des mesures supplémentaires
telles que le déplacement du poste, l’utilisation de câbles blindés,
l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone
de travail.
2-4. Proposition californienne 65 Avertissements
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des mal-
formations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Ce produit contient des produits chimiques, notamment du
plomb, dont l’État de Californie reconnaît qu’ils provoquent
des cancers, des malformations congénitales ou d’autres
problèmes de procréation. Se laver les mains après
utilisation.
2-5. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
is available as a free download from the American Welding Society at
http://www.aws.org or purchased from Global Engineering Documents
(phone: 1-877-413-5184, website: www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Glob-
al Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for Welding and Cutting Containers that have Held Com-
bustibles, American Welding Society Standard AWS A6.0, from Global
Engineering Documents (phone: 1-877-413-5184,
website: www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protec-
tion Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:www.cga-
net.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Mississauga, Ontario, Canada L4W 5NS
(phone: 800-463-6727, website: www.csagroup.org).
Safe Practice For Occupational And Educational Eye And Face Protec-
tion, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web-
site: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org).
OSHA, Occupational Safety and Health Standards for General Indus-
try, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Super-
intendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The Na-
tional Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-6. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant issu d’un
soudage à l’arc (et de procédés connexes, y compris le soudage par
points, le gougeage, le découpage plasma et les opérations de
chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits
peuvent causer interférence à certains implants médicaux, p. ex. les
stimulateurs cardiaques. Des mesures de protection pour les porteurs
d’implants médicaux doivent être prises: Limiter par exemple tout accès
aux passants ou procéder à une évaluation des risques individuels pour
les soudeurs. Tous les soudeurs doivent appliquer les procédures
suivantes pour minimiser l’exposition aux CEM provenant du circuit de
soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induc-
tion. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-257722 Page 9
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbols And Definitions
. Some symbols are found only on CE products.
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not discard product (where applicable) with general waste.
Reuse or recycle Waste Electrical and Electronic Equipment (WEEE) by disposing at a designated collection
facility.
Contact your local recycling office or your local distributor for further information.
Safe37 2012−05
Safe57 2012−05
Wear dry insulating gloves. Do not touch electrode (wire) with bare hand. Do not wear wet or damaged gloves.
Protect yourself from electric shock by insulating yourself from work and ground.
Safe58 2012−06
Disconnect input plug or power before working on machine.
Safe5 2012−05
Keep your head out of the fumes.
Safe59 2012−05
Use forced ventilation or local exhaust to remove the fumes.
Safe60 2012−06
Use ventilating fan to remove fumes.
Safe61 2012−06
Keep flammables away from welding. Do not weld near flammables.
Safe62 2012−06
Welding sparks can cause fires. Have a fire extinguisher nearby, and have a watchperson ready to use it.
Safe63 2012−06
OM-257722 Page 10
?
Do not weld on drums or any closed containers.
Safe64 2012−06
Do not remove or paint over (cover) the label.
Safe20 2012−05
Drive rolls can injure fingers.
Safe32 2012−05
Welding wire and drive parts are at welding voltage during operation − keep hands and metal objects away.
Safe33 2012−05
Wear hat and safety glasses. Use ear protection and button shirt
collar. Use welding helmet with correct shade of filter. Wear complete
body protection.
Safe66 2012−06
Become trained and read the instructions before working on the
machine or welding.
Safe65 2012−06
3-2. Miscellaneous Symbols And Definitions
. Some symbols are found only on CE products.
On
Percent
Purge By Gas
Constant Voltage
I
2
Rated Welding
Current
Off
Run-In
Filter
A
Amperes
V
Volts
IP
Degree Of Protec-
tion
Power Connection
Gas IN
Increase
Wire Feed
Cold Jog (Inch)
Towards Work-
piece
Supplementary
Protector
Trigger Hold On
U
1
Input Voltage
I
1
Input Current
Input
Constant Current
Trigger Hold Off
Read Instructions
OM-257722 Page 11
SECTION 4 − SPECIFICATIONS
4-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located inside the door. Use rating label to determine input power requirements and/or rated
output. For future reference, write serial number in space provided on back cover of this manual.
4-2. Unit Specifications
Type of
Input
Power
Welding
Power
Source
Type
Wire Feed
Speed*
Wire Diameter
Range
Input
Welding
Circuit
Rating
Max. Wire
Spool Capacity
Overall
Dimensions
Weight
Open-Circuit/
Arc Voltage,
14 − 110
Volts DC
Constant
Voltage (CV)
Or Constant
Current (CC)
DC Power
Source Only
25 − 800 ipm
(0.64 − 20.3
mpm) Depending
On Arc Voltage
Solid Wire:
.023 - .052 in.
(0.6 To 1.3 mm)
Flux Cored:
.030 - 5/64 in.
(0.8 To 2 mm)
425 Amperes
At 60%
Duty Cycle
300 Amperes
At 100%
Duty Cycle
45 lb (20.4 kg),
12 in. (304 mm)
Length: 21 in.
(533 mm)
Width: 9 in.
(229 mm)
Height: 15-1/2 in.
(394 mm)
34.5 lb
(15.6 kg)
*See Section 4-4 for detailed wire type, size, and rated speed range
4-3. Environmental Specifications
A. IP Rating
IP Rating
IP23
This equipment is designed for outdoor use. It may be stored,
but is not intended to be used for welding outside during precipitation unless sheltered.
IP23 2014−06
4-4. Wire Type, Size, and Feed Speed Capability Table
Motor Speed Wire Type Wire Size Rated Speed Range*
Standard All
Solid Wire:
.023 - .052 in.
(0.6 To 1.3 mm)
Flux Cored:
.030 - 5/64 in.
(0.8 To 2 mm)
50 to 780 ipm
(1.3 -19.8 mpm)
*Rated speed range per IEC 60974-5
4-5. Gun Recommendation Table
Process Gun
GMAW − Hard or Cored Wires Bernard Q-Gun, S-Gun
Tregaskiss Tough Gun
Roughneck C-Series
FCAW − Self-Shielding Wires Bernard Dura-Flux Gun
Ironmate Series
OM-257722 Page 12
SECTION 5 − INSTALLATION
5-1. Equipment Connection Diagram
Ref. 257 819-D
4
5
9
2
10
7
8
6
1
! Turn Off wire feeder and
welding power source. Stop
engine on welding
generator.
! Do not move or operate
equipment where it could
tip.
! Use only with CC/CV DC
power sources.
1 Welding Power Source
2 Gas Hose
3 Weld Cable To Feeder
4 Work Cable To Workpiece
Weld cable and work cable connec-
tions to power source (DCEN/
DCEP) are dependant on wire type.
. Since feeder is not polarity sen-
sitive, there is no need for an
electrode polarity switch.
5 Workpiece
6 Voltage Sensing Clamp
Connect voltage sensing clamp to
workpiece.
7 Gun
8 Gun Trigger Receptacle
9 Wire Feeder
10 Gas Cylinder
Use of shielding gas is dependant
on wire type.
. Shielding gas pressure not to
exceed 100 psi (689 kPa).
3
5-2. ArcReach Applications
. To take advantage of the ArcReach features, the Suitcase X−treme ArcReach wire feeder must be used with an ArcReach Control, or an ArcReach
compatible welding power source. The Suitcase X−treme ArcReach wire feeder may also be used as a standard feeder on any Non−ArcReach
power source.
. This wire feeder has the ability to associate with an ArcReach compatible welding power source at power up, or when wire feeder is triggered.
For either method, the welding power source must be in an Output On mode. See instructions in the welding power source Owner’s Manual.
5-3. Associating Wire Feeder To ArcReach Compatible Power Source Or
ArcReach Control
Associating wire feeder to an ArcReach compatible welding power source at power up
. The welding power source must be in an Output On mode. See instructions in the welding power source Owner’s Manual.
. On wire feeder, set CC/CV switch to CV mode. The feeder will not associate with another piece of equipment if the feeder is set to CC mode.
1 Turn on the welding power source and wire feeder.
2 Decimal points on feeder voltmeter will blink.
3 When decimal points stop blinking and a voltage is displayed, the feeder and power source are associated. The association process may take
several seconds to complete.
4 Dependent on the capabilities of the ArcReach power source, the feeder may set the mode switch to the correct wire mode. The wire mode is
determined by the polarity of the connections to the feeder.
5 Use voltage control on feeder to adjust preset weld voltage.
6 The voltmeter on the feeder will alternate between preset weld voltage and open circuit voltage while idle or weld voltage at the wire feeder while
welding.
OM-257722 Page 13
Associating wire feeder to an ArcReach compatible welding power source or ArcReach Control when the wire feeder is triggered
. The welding power source must be in an Output On mode. See instructions in the welding power source Owner’s Manual.
. On feeder, set CC/CV switch to CV mode. The feeder will not associate with another piece of equipment if the feeder is set to CC mode.
1 Turn on the welding power source and wire feeder. The wire feeder voltage display will alternate between three dashes and open circuit voltage.
2 Pull trigger on gun. Do not strike an arc.
3 Decimal points on feeder voltmeter will blink.
4 When decimal points stop blinking and a voltage is displayed, the feeder and power source or ArcReach Control are associated. Release trigger
on gun. The association process may take several seconds to complete.
5 Dependent on the capabilities of the ArcReach power source, the feeder may set the mode switch to the correct wire mode. The wire mode is
determined by the polarity of the connections to the feeder.
6 Use voltage control on feeder to adjust preset weld voltage.
7 The voltmeter will alternate between preset voltage and open circuit voltage while idle or weld voltage at the wire feeder while welding.
5-4. Equipment Setup
. To take advantage of the ArcReach features, the Suitcase X-treme ArcReach wire feeder must be used with an ArcReach Control, or an ArcReach
compatible welding power source. The Suitcase X-treme ArcReach wire feeder may also be used as a standard feeder on any Non-ArcReach
power source.
During ArcReach operation, weld voltage and wire feed speed are set at the wire feeder front panel. Voltage control is disabled at the welding power
source.
Using the Suitcase X-treme ArcReach wire feeder with an ArcReach compatible welding power source or ArcReach Control
1 For the wire feeder to control the welding power source, the wire feeder and power source, or wire feeder and ArcReach Control must be
associated. If the wire feeder is not associated to the welding power source or ArcReach Control, the wire feeder will try to associate to a welding
power source or ArcReach Control when the trigger is pulled. See Section 5-3 to associate the wire feeder to an ArcReach compatible power
source or ArcReach control.
2 When association is complete, the voltage display on the wire feeder will alternate between preset voltage and open circuit voltage. The preset
voltages of the wire feeder and the welding power source should be within 0.5 volts of each other.
3 While adjusting the voltage control on the feeder, the voltage display will show only preset voltage. Ten seconds after the preset voltage has been
set, the display will alternate between preset voltage and open circuit voltage.
4 While welding, the welding power source will display weld voltage at the studs of the welding power source. The wire feeder displays weld voltage
at the wire feeder.
5 While welding, due to the voltage drops in the weld cable, the voltage display at the wire feeder and the voltage display at the welding power source
will not match. The preset voltage at the wire feeder must be set to a higher value to compensate for the voltage drop of the weld cable. Example:
if welding voltage of 18 volts is desired at the wire feeder and there is a 4 volt drop in the weld cable, the preset voltage at the wire feeder should
be 22 volts (18V + 4V = 22V).
6 When the wire feeder and welding power source or ArcReach Control are associated, they will stay associated until either unit is turned off. The
wire feeder can lose power for up to ten seconds and still recover its association with the welding power source or ArcReach Control. This is for
situations where the wire feeder may momentarily lose power due to a prolonged short circuit condition in the welding process.
7 If the CC/CV switch on the feeder is changed to CC mode, the feeder will lose its association with the welding power source or ArcReach Control.
To re-establish the association, set switch to CV mode and restart the association process.
Using the Suitcase X-treme ArcReach with a Non-ArcReach compatible welding power source
1 The wire feeder may be used with any constant voltage (CV) or constant current (CC) DC welding power source.
2 Set CC/CV switch in feeder to match output of power source.
3 The wire feeder will automatically work on a non-ArcReach compatible welding power source. There are no switches or jumpers to change.
4 The ArcReach features will not be available.
5 The voltage knob on front panel will be non-functional.
6 If the feeder is set to CC, the voltage display on the wire feeder will alternate between CC and open circuit voltage when not welding.
7 While welding, the voltage display on the wire feeder will display weld voltage at the wire feeder.
Notes
OM-257722 Page 14
5-5. Installing Drive Rolls
257 817-B
Installing Drive Rolls:
1 Drive Securing Roll Nut
2 Drive Roll Carrier
Turn nut one click until lobes of nut
line up with lobes of drive roll carrier.
3 Drive Roll
Slide drive roll onto drive roll carrier.
Turn nut one click.
Repeat procedure for top drive roll.
Cleaning Drive Rolls:
Remove drive rolls, and clean
grooves using a wire brush.
Installing Drive Rolls
3
1
2
OM-257722 Page 15
5-6. Connecting Welding Gun And Voltage Sensing Clamp
256 617-A / 257 810-D
! Turn Off wire feeder and
welding power source.
Stop engine on welding
generator.
! Weld voltage is present at
voltage sensing clamp
when wire feeder and
welding power source are
on. This condition exists
even if wire feeder light
and meters are off.
! Turn off wire feeder or
welding power source be-
fore handling or moving
voltage sensing clamp.
1 Gun Securing Knob
2 Gun Block
3 Gun Power Pin
4 Power Pin Groove
5 Gun Locking Tab
Loosen gun securing knob, insert
gun power pin into gun block. Po-
sition power pin as close as pos-
sible to drive rolls without touch-
ing. Align the gun power pin
groove with the gun locking tab.
Tighten gun securing knob.
If the gun power pin does not
have a groove, loosen knob to ro-
tate the gun locking tab 180 de-
grees. This prevents the the gun
locking tab from interfering with
the gun power pin when inserted
into the gun block. Insert the gun
power pin into the gun block. Pos-
ition power pin as close as pos-
sible to drive rolls without touch-
ing them. Tighten gun securing
knob.
6 Gun Trigger Plug
7 Gun Trigger Receptacle
Connect gun trigger plug to gun
trigger receptacle.
See Section 6-2 to make wire
speed dual schedule connec-
tions to gun trigger receptacle.
8 Voltage Sensing Clamp
Connect voltage sensing clamp
to workpiece.
3
6
7
Internal Side View
8
Gun Locking Tab In Place
Gun Locking Tab Out Of Place
5
5
4
2
1
OM-257722 Page 16
5-7. Connecting Shielding Gas
256 620-A
NOTICE − This feeder has a shield-
ing gas filter that requires special
attention when cleaning. See Sec-
tion 7-3 for proper cleaning instruc-
tions.
1 Gas Hose With 5/8-18
Right-hand Thread Fittings
(Customer Supplied)
. Tighten gas hose fitting to a
maximum of 100 in. lbs (12
N
.
m).
2 Shielding Gas Cylinder
. Shielding gas pressure not to
exceed 100 psi (689 kPa).
3 Valve
4 Flowmeter
Close valve on cylinder when fin-
ished welding.
1
Rear View
2
3
4
5-8. Connecting Weld Cable
! Turn Off wire feeder and
welding power source. Stop
engine on welding
generator.
1 User-Supplied Weld Cable
Follow wire manufacturer’s recom-
mendations for weld cable polarity.
2 Male Connector
3 User-Supplied Female
Connector
Connect male and female
connectors.
256 621-A
2
3
1
OM-257722 Page 17
5-9. Selecting Cable Sizes*
! Turn off power before connecting to weld output terminals.
! Do not use worn, damaged, undersized, or repaired cables.
NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source
is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine
cable size.
Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit
Not Exceeding***
100 ft (30 m) or Less
150 ft
(45 m)
200 ft
(60 m)
250 ft
(70 m)
300 ft
(90 m)
350 ft
(105 m)
400 ft
(120 m)
Welding
Amperes
10 − 60%
Duty
Cycle
AWG (mm
2
)
60 − 100%
Duty Cycle
AWG (mm
2
)
10 − 100% Duty Cycle
AWG (mm
2
)
100 4 (20) 4 (20) 4 (20) 3 (30) 2 (35) 1 (50) 1/0 (60) 1/0 (60)
150 3 (30) 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 3/0 (95)
200 3 (30) 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 4/0 (120)
250 2 (35) 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x2/0 (2x70)
300 1 (50) 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95)
350 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x3/0 (2x95) 2x4/0 (2x120)
400 1/0 (60) 2/0 (70) 3/0 (95) 4/0 (120) 2x2/0 (2x70) 2x3/0 (2x95) 2x4/0 (2x120) 2x4/0 (2x120)
* This chart is a general guideline and may not suit all applications. If cable overheats, use next size larger cable.
**Weld cable size (AWG) is based on either a 4 volts or less drop or a current density of at least 300 circular mils per ampere.
( ) = mm
2
for metric use
***For distances longer than those shown in this guide, call a factory applications rep. at 920-735-4505 (Miller) or 1-800-332-3281 (Hobart).
Ref. S-0007-L 2015−02
Notes
OM-257722 Page 18
5-10. Installing And Threading Welding Wire
Ref. 257 806-B
Pull and hold wire; cut off end.
6 in.
(150 mm)
1
2
3
WOOD
. Hold wire tightly
to keep it from
unraveling.
Tighten
Clockwise
Installing Wire And Adjusting Hub
Tension:
1 Retaining Nut
2 Hub Tension Adjustment Knob
Remove retaining nut, and install spool
so hub pin fits spool hole. Reinstall re-
taining nut.
Adjust tension knob so only a slight force
is needed to turn spool.
. Do not over tighten tension knob. It
is not necessary to use any tools to
tighten the knob.
Threading Welding Wire:
3 Pressure Adjustment Knob
Lay gun cable out straight.
Open pressure assembly. Hold wire
tightly and cut off end. Guide wire
between alignment pins, into drive roll
grooves, and into gun liner.
Close pressure assembly and tighten
pressure adjustment knob enough to
feed wire. Press jog switch until wire
comes out of gun.
To set proper drive roll pressure, release
the pressure on the drive rolls by loosen-
ing the pressure adjustment knob. Posi-
tion gun at about a 45 degree angle, with
nozzle about two inches from a wooden
surface. While feeding the wire against
the wooden surface, increase the pres-
sure to one half turn past the point where
the wire stops slipping. If the wire slips at
maximum hand-tight pressure, there
may be other problems. Check the gun
liner, spool tension, contact tip and drive
roll wear, as all these can cause wire
feeding problems.
Cut off wire, and close door.
5-11. Motor Board (PC1) DIP Switch Settings
247 678-B
1 Motor Control Board PC1
2 DIP Switch SW1
3 LED5
. DIP switch SW1 is used to match the
performance of PC1 to the character-
istics of the motor used in the feeder.
Setting SW1 as shown will help insure
that PC1 and motor are matched for
optimal performance.
If protective coating is present, remove be-
fore setting DIP switch. It is not necessary
to reapply the protective coating.
Set switch positions 1 and 2 so the de-
pressed section of both tabs are toward 1
and 2 as labeled on the switch. As shown
in illustration.
When feeder is powered up, LED 5 on the
motor control board will blink four times.
This blinking indicates everything is work-
ing properly and the DIP switch is set cor-
rectly.
After LED 5 is done blinking, it will be either
red or green. Red indicates that the feeder
is connected with electrode positive. Green
indicates feeder is connected with elec-
trode negative.
12
OPEN
RC111
OM-257722 Page 20
Accessing DIP Switch
1 Lens
DIP switch is located under the lens
next to the displays.
2 Lens Screws
Remove three screws.
Loosen upper right hand screw to
rotate lens enough to access DIP
switch.
Replace three screws removed
earlier.
Tighten upper right hand screw.
. The two upper screws must
engage the backing plate to
properly secure the front panel.
2
1
12345
−−−−O P E N −−−
12345
−−−−O P E
N −−−−
Factory default
DIP switch set-
tings to display
wire speed as
meters per
minute
Factory default
DIP switch set-
tings to display
wire speed as
inches per
minute
5-12. Meter Board (PC22) DIP Switch Settings
DIP Switch Settings:
Display Hold OFF − Set switch 1 so the depressed section is toward OPEN as labeled on the switch.
Displays will not hold values. The voltage displayed while welding is an average reading over a time span of 6 to 8 sec-
onds. If the weld time is less than 8 seconds, the voltage displayed may not be accurate.
Display Hold ON (Factory Default) − Set switch 1 so the depressed section is toward 1 as labeled on the switch.
Displays will hold their last value for five seconds after the trigger is released. The voltage displayed while welding is
an average reading over a time span of 6 to 8 seconds. If the weld time is less than 8 seconds, the voltage displayed
may not be accurate.
12345
−−−−OPEN−−−
12345
−−−OPEN−−−
Ref. 273 255-B
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Miller MG203123V Owner's manual

Category
Welding System
Type
Owner's manual
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